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Abstract
A numerical model of coupled heat transfer and fluid flow is developed for the twin-belt (Hazelett) casting process. The model considers a generalized energy equation that is valid for the solid, liquid, and mushy zones in the cast. A k-∊ turbulence model is used to calculate the turbulent viscosity in the melt pool. The process variables considered are the belt speed, strip thickness, nozzle width, and cooling conditions of the belt. Aluminum alloys 3105 and 5182 and steel 1020 are used as cases for the modeling study. The temperature fields in the solid and liquid regions of the alloy considered along with the velocity fields in the mushy and liquid regions are presented and discussed for varying process conditions. The effects of varying the heat transfer coefficient along the belt caster were studied. From the computed flow and temperature fields, the local cooling rates in the cast and the trajectories of inclusions were computed. The cooling rate calculations were used to predict the dendrite arm spacings in the cast. The inclusion trajectories confirm earlier findings on the distribution of inclusion particles in near-horizontal casters.